Front rail having controlled thickness for energy absorption

ABSTRACT

A frame rail for a vehicle that is provided between vehicle frame and the bumper of a vehicle that has a thickness that varies from the front end of the rail to the back end of the rail. The compressive strength of the rail increases from the front end of the rail to the back end of the rail. The rail is rectangular in shape and the thickness of the rail is continuously increased to improve progressive crush characteristics of the rail under an oblique loading. A rail may be provided by providing a tubular rail having a plurality of ring shaped segments that have incrementally increasing thickness. Alternatively, the rail may have a uniformly increasing thickness from the front end to the back end.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to front rail structures that have controlled thickness that increases the strength of the rail structure from front to rear causing the rail to collapse during a crash event in a progressive manner instead of bending globally.

2. Background Art

Energy absorbing tubular structures are known to be used in vehicles to absorb energy during an impact event. Examples of such energy absorbing tubular structures are disclosed in U.S. Pat. Nos. 6,588,830 and 6,899,195. Energy absorbing tubular structures are seldom subjected to solely axial loading or solely bending loading during an actual collision event. Generally, the actual impact loading of a vehicle during a collision event is a combination of both axial and global bending collapse modes.

SUMMARY OF THE INVENTION

The present invention is directed to providing an improved energy absorbing front rail structure for vehicles that is designed to enable the front rail to collapse in a progressive manner from front to rear while preventing early global bending in the rail.

According to one aspect of the present invention, a front frame rail apparatus for a vehicle is provided that is attached between a frame rail and a bumper of the vehicle. The apparatus comprises at least one elongated tubular rail having a front end and a back end. The thickness of the rail varies from the front end of the rail to the back end of the rail with the compressive strength of the rail increasing from the front end of the rail to the back end of the rail.

According to another aspect of the present invention, the rail may be rectangular in shape. The thickness of the tube, or rail, is determined as follows:

${t(x)} \geq {t_{0}\left\lbrack {1 + \frac{3{ax}\; \tan \; \beta}{b^{2} + {3{ab}}}} \right\rbrack}$

where:

-   -   x is the distance from the front of the tube     -   t₀ is the initial column thickness at x=0     -   t(x) is the thickness of the tube at a distance x from the front         of the tube     -   a is the height of the tube     -   b is the width of the tube     -   β is the angle between the normal direction relative to the         plane of the rigid wall and the central axis of the tubular         member.

According to another aspect of the invention, a front frame rail apparatus for a vehicle is provided that is attached between a frame rail and a bumper of the vehicle. The apparatus may comprise a plurality of ring-shaped tubular segments that each have a different thickness (t). The term “ring shaped” as used herein includes square, rectangular, round, oval and other tubular shapes generally. The plurality of ring-shaped tubular segments are joined together on axial ends along a common axis. Tubular segments are aligned in sequence from a front end of the apparatus to a back end of the apparatus. Each of the tubular segments has an increased thickness relative to the segment forward and adjacent to the tubular segment.

According to other aspects of the invention, a plurality of ring-shaped segments may each have a uniform length. The increasing incremental thickness of the plurality of ring-shaped segments may increase in a uniform progression.

According to another aspect of the present invention, a front frame rail apparatus for a vehicle is provided that is attached between a frame rail and a bumper of the vehicle that comprises a tubular member having a front end and a back end. The tubular member has a constant rate of increase in thickness from the front end to the back end.

According to another aspect of the invention, the rate of increase in thickness may be defined as follows:

t=cx+t ₁ , c>0

wherein:

x=the longitudinal distance from the front end of the tubular member

t=the thickness of the tubular member at longitudinal location “x”

c=the rate of increase in thickness

t₁=the thickness of the tubular member at the front end.

According to still further aspects of the invention, the periphery of the outer surface of the tubular member may increase uniformly from the front end to the back end. The periphery of the inner surface of the tubular member may decrease uniformly from the front end to the back end. The periphery of the outer surface of the tubular member may increase uniformly from the front end to the back end with the inner surface of the tubular member decreasing uniformly from the front end to the back end.

According to still another aspect of the invention relating to the method of forming the tubular member, the tubular member may be formed as a tailor-welded blank that is then formed into a tubular shape. Alternatively, the tubular member may be roll formed into a blank that has increasing thickness in one direction that is rolled to form the tubular shape about an axis that is perpendicular to the one direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial front perspective view of a truck or sport utility vehicle frame;

FIG. 2 is a partial front perspective view of a car frame shown with a portion of the “body-in-white” structure;

FIG. 3 is a diagrammatic cross-sectional view of a tubular rail formed as a plurality of ring-shaped segments;

FIG. 4 is a diagrammatic cross-sectional view of a tubular member that is formed to have a uniformly increasing thickness from the front end to the back end;

FIG. 5 is a diagram illustrating the geometry of a rectangular rail under oblique loading;

FIG. 6 is a cross-sectional view taken along the line 6-6 in FIG. 5;

FIG. 7 is a top plan view showing the rectangular beam in a vertical configuration; and

FIG. 8 is a top plan view showing a rectangular beam in a horizontal configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to FIG. 1, a partial frame 10 of a truck or sport utility vehicle on which a body is built. Referring to FIG. 2, a partial unibody frame 12 is shown with part of a “body-in-white” unibody vehicle structure 14. Referring to both FIGS. 1 and 2, the frames 10, 12 provide or are connected to an engine mount zone 16. Both of the frames 10 and 12 are connected through the respective engine mount zones 16 to a pair of front rails 20. The front rails each have a variable thickness that may be provided in different embodiments that will be more fully described below.

Referring to FIG. 3, a diagram of a front rail, or tubular member 20, made according to one embodiment of the present invention is illustrated. A front tubular segment 22 is provided at the front end of the tubular member 20 between the tubular member 20 and a bumper 24 of the vehicle. A back tubular segment 26 is provided at the back end of the tubular member 20 that is connected through either of the engine mount zones 16 to one of the vehicle frames 10, 12. A plurality of intermediate segments 30 are provided between the front tubular segment 22 and the back tubular segment 26. The thickness t₁-t₆ of the six tubular segments increase incrementally from the front tubular segment 22 to the back tubular segment 26. In one embodiment of the invention, the incremental increase in thickness is uniform in that the increment of increase from a front tubular segment 22 to the first intermediate segment 30 is the same as incremental thickness increase for each segment up to thickness t₆ of the back tubular segment 26. The depiction of six segments is merely an illustrative example. More or fewer segments could be provided depending upon design and performance parameters.

The tubular segments may be square or rectangular. Alternatively, the tubular segment may be of another shape such as round or oval. The tubular member 20 is designed to manage energy during a frontal impact.

Starting at around 8 to 10 degrees, prior art rails that are designed to progressively fold in an angular frontal impact tend to buckle instead which eliminates the progressive folding of the rail. The tubular member 20 progressively folds during frontal impact crashes at angles from 0 to 40 degrees to provide progressive folding without adding weight to the rail structure. The tubular member 20 progressively folds and starts bending only beyond 45 degrees in oblique impact as more specifically described with reference to FIGS. 3-5 below.

Tubular member 20 may be manufactured as a tailor welded blank comprising a plurality of cut pieces of sheet metal that have incrementally increased thickness. Alternatively, the blank can be formed in a rolling process to obtain the thickness profile shown in FIGS. 3 or 4. The cut pieces of sheet metal are welded on their edges to form a blank before being formed into a tube. The cut pieces may be laser welded or welded by other conventional welding techniques. After the segments are welded, the blank may be rolled to form a tube with desired stepped cross section. Rolling process may be performed on a tailor welded blank while leaving distinct steps between the adjacent segments. Alternatively, transition areas may be provided between the segments.

Referring to FIG. 4, an alternate embodiment of the invention is shown where a tubular member 32 is provided that is formed with a constantly increasing thickness from front to rear. The thickness of the tube increases as a normal slope function, t=cx+t₁, c>0. The increase in thickness tubular member 32 has a front end 34 that is attached directly, or indirectly to a bumper 24. The tubular member 32 has a back end 36 that is attached directly, or indirectly to the vehicle frame 28. The thickness of the tubular member 32 has a variable thickness that increases to provide the progressive folding even in oblique impacts up to 45 degrees. In one embodiment of the invention, the thickness of the tubular member may increase in thickness at a constant rate. In another embodiment, the rate of increase can be non-linear, e.g., according to a quadratic function. The tubular member 32 may be rolled to provide a blank of reduced thickness. The blank is then shaped into a tube in a manufacturing process similar to the process used to form seamless pipe. Alternatively, the blank may be shaped into another cross-sectional shape, such as a C-section, a “hat-section,” or the like and then assembled by conventional processes to make a rail.

Referring to FIGS. 5 and 6, the geometry of the rectangular rail 32 under oblique loading according to the present invention is illustrated. The description of the tubular rail 32 is also believed to be representative of the tubular rail 20 of FIG. 3 and references below to tubular rail 32 should be understood as being applicable to tubular rail 20. The rectangular tubular member 32 has a top wall 46 and a bottom wall 48. The walls of the tubing have a thickness t(x). The height of the tubular member 32 is designated as (a). The rectangular tubular member 32 has right side wall 42 and left side wall 44. The width of the tubular member 32 is designated as (b). The angle of the oblique impact is represented by (β) which is the angle between the direction normal to the plane of the rigid wall and the central axis of the tubular member 32. (x) is the distance from the front end 34 along the axial length of the tubular member 32.

Referring to FIG. 7, a tubular member 32 is shown oriented vertically in an impact. The side walls 42 and 44 of the tube shown in FIG. 5 is oriented vertically as the tubular member 32 is driven into an obliquely oriented target impact wall 50.

Referring to FIG. 8, the tubular member 32 may be oriented with the top wall and bottom wall extending horizontally while driven into the obliquely oriented target impact wall 50. In either orientation, the increasing thickness of the segments or continuously increasing thickness of the tube results in progressive bending even when the force is offset by an angle up to β of 45 degrees. Stated another way, the new designs with the constantly increasing thickness may withstand up to 45 degrees of obliquely angled force application before global bending occurs in the tubular members 22, 32.

While the above example is described in reference to a front rail assembly, the invention is believed to be equally applicable and equivalent to rear frame rails. The references to the front and rear of the rail would of course be reversed for application to rear frame rail applications.

While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. 

1. A frame rail apparatus for a vehicle that is attached between a frame rail and a bumper of the vehicle, the apparatus comprising: an elongated tubular rail having a front end and a back end, the thickness of the rail varies from the front end of the rail to the back end of the rail with the compressive strength of the rail increasing from the front end of the rail to the back end of the rail.
 2. The apparatus of claim 1 wherein the rail is rectangular in shape and the geometry of the rail under oblique loading is provided wherein the thickness of the tube is: ${t(x)} \geq {t_{0}\left\lbrack {1 + \frac{3{ax}\; \tan \; \beta}{b^{2} + {3{ab}}}} \right\rbrack}$ where: x is the distance from the front of the tube t₀ is the initial column thickness at x=0 t(x) is the thickness of the tube at a distance x from the front of the tube a is the height of the tube b is the width of the tube β is the angle between the direction normal to the plane of the rigid wall and the central axis of the tubular member.
 3. The apparatus of claim 1 wherein the tubular rail is formed to have a plurality of ring shaped segments that have incrementally increasing thickness.
 4. The apparatus of claim 3 wherein the plurality of ring shaped segments have each a uniform length.
 5. The apparatus of claim 3 wherein the increasing incremental thickness of the plurality of ring shaped segments increase in a uniform progression.
 6. The apparatus of claim 1 wherein the tubular rail has a uniformly increasing thickness from the front end to the back end.
 7. The apparatus of claim 6 wherein the periphery of the outer surface of the tubular member increases uniformly from the front end to the back end.
 8. The apparatus of claim 6 wherein the periphery of the inner surface of the tubular member decreases uniformly from the front end to the back end.
 9. The apparatus of claim 6 wherein the periphery of the outer surface of the tubular member increases uniformly from the front end to the back end and the inner surface of the tubular member decreases uniformly from the front end to the back end.
 10. A frame rail apparatus for a vehicle that is attached between a frame rail and a bumper of the vehicle, the apparatus comprising: a plurality of ring shaped tubular segments that each have a different thickness (t), are joined together on axial ends about a common axis, the tubular segments being aligned in sequence from a front end of the apparatus to a back end of the apparatus, wherein each of the tubular segments has an increased thickness relative to the segment forward and adjacent the tubular segment.
 11. The apparatus of claim 10 wherein the plurality of ring shaped segments have each a uniform length.
 12. The apparatus of claim 10 wherein the increasing incremental thickness of the plurality of ring shaped segments increase in a uniform progression.
 13. A front frame rail apparatus for a vehicle that is attached between a frame rail and a bumper of the vehicle, the apparatus comprising: a tubular member having a front end and a back end, the tubular member having a constant rate of increase in thickness from the front end to the back end.
 14. The apparatus of claim 13 wherein the rate of increase in thickness is defined as follows: t=cx+t ₁ , c>0 wherein: x=the longitudinal distance from the front end of the tubular member t=the thickness of the tubular member at longitudinal location “x” c=the rate of increase in thickness t₁=the thickness of the tubular member at the front end.
 15. The apparatus of claim 13 wherein the periphery of the outer surface of the tubular member increases uniformly from the front end to the back end.
 16. The apparatus of claim 13 wherein the periphery of the inner surface of the tubular member decreases uniformly from the front end to the back end.
 17. The apparatus of claim 13 wherein the periphery of the outer surface of the tubular member increases uniformly from the front end to the back end and the inner surface of the tubular member decreases uniformly from the front end to the back end.
 18. The apparatus of claim 13 wherein the tubular member is initially formed as a tailor welded blank and is then formed into a tubular shape.
 19. The apparatus of claim 13 wherein the tubular member is roll formed into a blank that has increasing thickness in one direction that is rolled to form the tubular shape about an axis that extends in the one direction. 